Shingle With Reinforced Nail Zone And Method Of Manufacturing

ABSTRACT

A roofing shingle ( 74 ) includes an asphalt-coated sheet ( 18 ) having a tab portion ( 78 ) normally exposed on a roof and a headlap portion ( 76 ) normally covered-up on a roof. The headlap portion has a lower zone ( 76 A) that extends longitudinally between a first end ( 74 A) and a second end ( 74 B) of the roofing shingle adjacent the tab portion, and an upper zone ( 76 B) adjacent the lower zone. At least a portion of the asphalt-coated sheet has granules adhered thereto. A reinforcement member ( 19 ) is adhered to the lower zone of the headlap portion.

TECHNICAL FIELD

This invention relates to a shingle, such as a roofing shingle, and inparticular, to a roofing shingle having an improved nail zone.

BACKGROUND OF THE INVENTION

Asphalt-based roofing materials, such as roofing shingles, roll roofingand commercial roofing, are installed on the roofs of buildings toprovide protection from the elements, and to give the roof anaesthetically pleasing look. Typically, the roofing material isconstructed of a substrate such as a glass fiber mat or an organic felt,an asphalt coating on the substrate, and a surface layer of granulesembedded in the asphalt coating.

A common method for the manufacture of asphalt shingles is theproduction of a continuous sheet of asphalt material followed by ashingle cutting operation which cuts the material into individualshingles. In the production of asphalt sheet material, either a glassfiber mat or an organic felt mat is passed through a coater containinghot liquid asphalt to form a tacky, asphalt coated sheet. Subsequently,the hot asphalt coated sheet is passed beneath one or more granuleapplicators which discharge protective and decorative surface granulesonto portions of the asphalt sheet material.

In certain types of shingles, it is especially desired that the shinglesdefine a sufficiently wide area, often known in the industry as the“nail zone,” in order to make installation of roofs using shingles, suchas laminated shingles, more efficient and secure. One or more lines orother indicia painted or otherwise marked longitudinally on the surfaceof the shingle may define such a nail zone. It is especially desiredthat the shingles define a nail zone that allows the installers to havesome latitude in the nail placement.

Additionally, the leading edge of some shingles may experience lift offin high wind situations. Therefore, there is also a need for shingleswhere the shingles have a sufficiently high nail pull-through value sothat the installed shingles have improved performance in high windsituations.

SUMMARY OF THE INVENTION

The above objects as well as other objects not specifically enumeratedare achieved by a roofing shingle including an asphalt-coated sheethaving a tab portion normally exposed on a roof and a headlap portionnormally covered-up on a roof. The headlap portion has a lower zone thatextends longitudinally between a first end and a second end of theroofing shingle adjacent the tab portion, and an upper zone adjacent thelower zone. At least a portion of the asphalt-coated sheet has granulesadhered thereto. A reinforcement member is adhered to the lower zone ofthe headlap portion.

A second embodiment of the invention the roofing shingle is a laminatedroofing shingle including an underlay member and an overlay memberattached to the underlay member. The overlay member has a tab portionnormally exposed on a roof and a headlap portion normally covered-up ona roof, and the headlap portion has a lower zone adjacent the tabportion and an upper zone adjacent the lower zone, wherein at least aportion of the overlay member has granules adhered thereto. The overlaymember has a first height and the underlay member has a second height,the second height being one of less than one-half the first height andequal to one-half the first height, the overlay member and the underlaymember thereby defining a two layer portion and a single layer portionof the laminated shingle. At least a portion of the reinforcement memberis adhered to the single layer portion of the laminated shingle.

A third embodiment of the invention is method of making a laminatedshingle including coating a shingle mat with roofing asphalt to make anasphalt-coated sheet; adhering a reinforcement member to a portion ofthe asphalt-coated sheet; and covering the asphalt-coated sheet, andoptionally covering the reinforcement member, with granules to make agranule-covered sheet. The granule-covered sheet is divided into anoverlay sheet and an underlay sheet, wherein the overlay sheet has a tabportion normally exposed on a roof and a headlap portion normallycovered-up on a roof, and the headlap portion has a lower zone adjacentthe tab portion and an upper zone adjacent the lower zone. Thereinforcement member is adhered to the lower zone of the headlapportion, and the overlay sheet is laminated to the underlay sheet tomake the laminated shingle.

A fourth embodiment of the invention is a method of making a laminatedshingle including coating a shingle mat with roofing asphalt to make anasphalt-coated sheet; covering the asphalt-coated sheet with granules tomake a granule-covered sheet; and adhering a reinforcement member to aportion of the granule-covered sheet. The granule-covered sheet isdivided into an overlay sheet and an underlay sheet, wherein the overlaysheet has a tab portion normally exposed on a roof and a headlap portionnormally covered-up on a roof. The headlap portion has a lower zoneadjacent the tab portion and ant upper zone adjacent the lower zone. Thereinforcement member is adhered to the lower zone of the headlapportion, and the overlay sheet is laminated to the underlay sheet tomake the laminated shingle.

A fifth embodiment of the invention is bundle of laminated roofingshingles stacked such that every other of the shingles is at least oneof inverted and turned 180 degrees relative to an adjacent one of theshingles. The shingles have an overlay laminated with an underlay. Theoverlay has a tab portion with cutouts normally exposed on a roof and aheadlap portion normally covered-up on a roof, and the headlap portionhas a lower zone adjacent the tab portion and an upper zone adjacent thelower zone. The lower zone has substantially no granules adheredthereto. The bundle defines a central area that substantiallyencompasses the lower zones of the stacked shingles. The laminatedroofing shingles are double-layered, wherein the lack of granules in thelower zones of the stacked shingles results in the central area of thebundle having a height substantially identical to a height of aremainder of the bundle outside of the central area.

A sixth embodiment of the invention is a method of reducing humping of abundle of stacked laminated roofing shingles. The shingles have anoverlay laminated with an underlay. The overlay has a tab portion withcutouts normally exposed on a roof and a headlap portion normallycovered-up on a roof. The headlap portion has a lower zone adjacent thetab portion and an upper zone adjacent the lower zone. The methodincludes providing the lower zone of the headlap portion havingsubstantially no granules adhered thereto. The shingles are stacked suchthat every other of the shingles is at least one of inverted and turned180 degrees relative to an adjacent one of the shingles, therebydefining a bundle of stacked laminated roofing shingles. The bundledefines a central area that substantially encompasses the lower zones.The laminated roofing shingles are double-layered, and the lack ofgranules in the lower zones of the stacked shingles results in thecentral area of the bundle having a height substantially identical to aheight of a remainder of the bundle outside the central area.

Various objects and advantages of this invention will become apparent tothose skilled in the art from the following detailed description of thevarious embodiments, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic elevational view of an apparatus for makingshingles according to the invention.

FIG. 2 is a perspective view of a laminated shingle having areinforcement member in accordance with this invention.

FIG. 3 is a schematic sectional view of a pair of laminated roofingshingles of the prior art stacked together, shown in exaggeratedthickness to illustrate humping of the stacked shingles.

FIG. 4 is a schematic sectional view of a pair of laminated roofingshingles according to the invention stacked together, shown inexaggerated thickness to illustrate how the reinforcement members ofadjacent shingles cooperate to reduce humping of the stacked shingles.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, there is shown in FIG. 1 an apparatus 10for manufacturing an asphalt-based roofing material according to theinvention. In the illustrated embodiment, the manufacturing processinvolves passing a continuous sheet 12 in a machine direction (indicatedby the arrows) through a series of manufacturing operations. The sheetusually moves at a speed of at least about 200 feet/minute (61meters/minute), and typically at a speed within the range of betweenabout 450 feet/minute (137 meters/minute) and about 800 feet/minute (244meters/minute). The sheet, however, may move at any desired speed.

In a first step of the illustrated manufacturing process, a continuoussheet of substrate or shingle mat 12 is payed out from a roll 14. Thesubstrate can be any type known for use in reinforcing asphalt-basedroofing materials, such as a non-woven web of glass fibers. The shinglemat 12 may be fed through a coater 16 where an asphalt coating isapplied to the mat 12. The asphalt coating can be applied in anysuitable manner. In the illustrated embodiment, the mat 12 contacts aroller 17, which is in contact with a supply of hot, melted asphalt. Theroller 17 completely covers the mat 12 with a tacky coating of hot,melted asphalt to define a first asphalt coated sheet 18. In otherembodiments, however, the asphalt coating could be sprayed on, rolledon, or applied to the sheet by other means. Typically, the asphaltmaterial is highly filled with a ground stone filler material, amountingto at least about 60-percent by weight of the asphalt/fillercombination.

A continuous strip of a reinforcement material or tape 19, as will bedescribed in detail herein, may then be payed out from a roll 20. Thereinforcement tape 19 adheres to the first asphalt coated sheet 18 todefine a second asphalt coated sheet 22. In one embodiment, thereinforcement tape 19 is attached to the sheet 18 by the adhesivemixture of the asphalt in the first asphalt coated sheet 18. Thereinforcement tape 19, however, may be attached to the sheet 18 by anysuitable means, such as other adhesives. In one embodiment, the tape 19is formed from polyester. In another embodiment, the tape 19 is formedfrom polyolefin, such as polypropylene or polyethylene, and may includeany polymeric material having the desired properties in the finishedproduct and which will endure the manufacturing environment. The tape19, can be formed from any material which preferably reinforce andstrengthens the nail zone of a shingle, such as, for example, paper,film, scrim material, and woven or non-woven fibers, such as glass,natural or polymer fibers, or the material may not provide such physicalproperties, but may simply provides an indicia of the nail zone.Additionally, it may be desirable to treat the tape to improve adhesion,such as through coatings, corona treatment, etching, surface treatments,providing perforations or other surface roughening, or adding fillers orother techniques to increase surface area for adhesion. Additionally, itmay be desirable to provide another adhesive between the tape and theasphalt coating to improve adhesion thereof.

The resulting second asphalt coated sheet 22 may then be passed beneatha series of granule dispensers 24 for the application of granules to theupper surface of the second asphalt coated sheet 22. The granuledispensers can be of any type suitable for depositing granules onto theasphalt coated sheet. A granule dispenser that can be used is a granulevalve of the type disclosed in U.S. Pat. No. 6,610,147 to Aschenbeck.The initial granule blender 26 may deposit partial blend drops ofbackground granules of a first color blend on the tab portion of thesecond asphalt coated sheet 22 in a pattern that sets or establishes thetrailing edge of subsequent blend drops of a second color blend (of anaccent color) and a third color blend (of a different accent color). Forpurposes of this patent application, the first color blend and thebackground granules are synonymous. The use of initially applied partialblend drops to define the trailing edge of subsequent blend drops isuseful where accurate or sharp leading edges are possible, but accuratetrailing edges at high shingle manufacturing speeds are difficult.

As is well known in the art, blend drops applied to the asphalt coatedsheet are often made up of granules of several different colors. Forexample, one particular blend drop that is supposed to simulate aweathered wood appearance might actually consist of some brown granules,some dark gray granules, and some light gray granules. When thesegranules are mixed together and applied to the sheet in a generallyuniformly mixed manner, the overall appearance of weathered wood isachieved. For this reason, the blend drops are referred to as having acolor blend, which gives an overall color appearance. This overallappearance may be different from any of the actual colors of thegranules in the color blend. Also, blend drops of darker and lightershades of the same color, such as, for example, dark gray and lightgray, are referred to as different color blends rather than merelydifferent shades of one color.

As shown in FIG. 1, the series of dispensers 24 includes four colorblend blenders 26, 28, 30, and 32. Any desired number of blenders,however, can be used. The final blender may be the background blender34. Each of the blenders may be supplied with granules from sources ofgranules, not shown. After the blend drops are deposited on the secondasphalt coated sheet 22, the remaining, uncovered areas are still tackywith warm, uncovered asphalt, and the background granules from thebackground blender 34 will adhere to the areas that are not alreadycovered with blend drop granules; After all the granules are depositedon the second asphalt coated sheet 22 by the series of dispensers 24,the sheet 22 becomes a granule covered sheet 40.

In one embodiment, the reinforcement tape 19 includes an upper surfaceto which granules substantially will not adhere. The reinforcement tape19, however, may include an upper surface to which granules will adhere.For example, the apparatus 10 may include any desired means fordepositing granules onto substantially the entire second asphalt coatedsheet 22, except for the portion of the second asphalt coated sheet 22covered by the tape 19, as best shown in FIG. 2. Alternately, granulesmay be deposited onto substantially the entire second asphalt coatedsheet 22, including the tape 19, but wherein the reinforcement tape 19includes an upper surface to which granules substantially will notadhere.

The granule covered sheet 40 may then be turned around a slate drum 44to press the granules into the asphalt coating and to temporarily invertthe sheet so that the excess granules will fall off and will berecovered and reused. Typically, the granules applied by the backgroundblender 34 are made up by collecting the backfall granules falling fromthe slate drum 44.

The granule covered sheet 40 may subsequently be fed through a rotarypattern cutter 52 which includes a bladed cutting cylinder 54 and abackup roll 56, as shown in FIG. 1. If desired, the pattern cutter 52can cut a series of cutouts in the tab portion of the granule coveredsheet 40, and cut a series of notches in the underlay portion of thegranule covered sheet 40.

The pattern cutter 52 may also cut the granule covered sheet 40 into acontinuous underlay sheet 66 and a continuous overlay sheet 68. Theunderlay sheet 66 may be directed to be aligned beneath the overlaysheet 68, and the two sheets may be laminated together to form acontinuous laminated sheet 70. As shown in FIG. 1, the continuousunderlay sheet 66 may be routed on a longer path than the path of thecontinuous overlay sheet 68. Further downstream, the continuouslaminated sheet 70 may be passed into contact with a rotary lengthcutter 72 that cuts the laminated sheet into individual laminatedshingles 74.

In order to facilitate synchronization of the cutting and laminatingsteps, various sensors and controls may be employed. For example,sensors, such as photo eyes 86 and 88 can be used to synchronize thecontinuous underlay sheet 66 with the continuous overlay sheet 68.Sensors 90 can also be used to synchronize the notches and cutouts ofthe continuous laminated sheet with the end cutter or length cutter 72.

In one embodiment, the reinforcement tape may be attached to the shinglemat 12 prior to the application of the asphalt coating, as shown at 19Ain FIG. 1. The tape 19A may be attached to the shingle mat 12 by anysuitable means, such as hot, melted asphalt, or other adhesives.

In another embodiment, the reinforcement tape may be attached to thegranule covered sheet 40, as shown at 19B in FIG. 1. The tape 19B may beattached to the granule covered sheet 40 by any suitable means, such ashot, melted asphalt, or other adhesives.

In another embodiment, the reinforcement tape may be attached to a lowersurface (downwardly facing as viewed in FIG. 1) of the mat 12, the firstasphalt coated sheet 18, the second asphalt coated sheet 22, or thegranule covered sheet 40, as shown at 19C and 19D in FIG. 1. The tape19C may be attached to the mat 12, the first asphalt coated sheet 18,the second asphalt coated sheet 22, or the granule covered sheet 40 byany suitable means, such as hot, melted asphalt, other adhesives, orsuitable fasteners. hi such an embodiment, the reinforcement tape 19Cand 19D may be attached to the lower surface of the nail zone of eitherof the overlay sheet 68 or the underlay sheet 66, thereby reinforcingand strengthening the nail zone as described herein.

It will be understood, however, that in any of the embodiments describedherein, reinforcement material may be applied as an extruded or liquidmaterial, such as a polymer, that will adhere to the mat 12, the firstsheet 18, the second sheet 22, the granule covered sheet 40, or thelower surface of the underlay sheet 66 or the overlay sheet 68.Additionally, the reinforcement material may be applied to the laminatedroofing shingle 74, as described below.

Referring now to FIG. 2, a laminated roofing shingle is shown generallyat 74. In the illustrated embodiment, the shingle 74 includes theoverlay sheet 68 attached to the underlay sheet 66 and has a first end74A and a second end 74B. The shingle 74 also includes a longitudinalaxis A. The overlay sheet 68 may include a headlap portion 76 and a tabportion 78. The headlap portion 76 may include a lower zone 76A and anupper zone 76B. The tab portion 78 defines a plurality of tabs 80 andcutouts 82 between adjacent tabs 80. In the illustrated embodiment, thetab portion 78 includes four tabs 80, although any suitable number oftabs 80 may be provided. The headlap portion 76 and the tabs 80 mayinclude one or more granule patterns thereon. Each cutout 82 has a firstheight H1. In the illustrated embodiment, the cutouts 82 are shown ashaving the same height H1. It will be understood however, that eachcutout 82 may be of different heights. A line B is collinear with anupper edge 82A of the cutouts 82 and defines an upper limit of anexposed region 84 of the underlay sheet 66. In the illustratedembodiment, the height of the exposed region 84 is equal to the firstheight H1, although the height of the exposed region 84 may be anydesired height, and the top of the cutouts need not be collinear asshown. In a shingle wherein the cutouts 82 have different heights, theline B may be collinear with an upper edge 82A of the cutout 82 havingthe largest height. In the illustrated embodiment, the overlay sheet 68has a second height H2.

The reinforcement tape 19 may be disposed longitudinally on the headlapportion 76. In the illustrated embodiment, the tape 19 extendslongitudinally from the first end 74A to the second end 74B of theshingle 74 within the lower zone 76A of the headlap portion 76. A loweredge 19A of the tape 19 may be spaced apart from the line B by adistance D1, and an upper edge 19B of the tape 19 may be spaced apartfrom the line B by a distance D2. In one embodiment, the distance D1 iswithin the range of from about ¼ inch to about ¾ inch. In anotherembodiment, the distance. D1 is about ½ inch. In one embodiment, thedistance D2 is within the range of from about 1¾ inches to about 2¼inches. In another embodiment, the distance D2 is about 2 inches. Thedistances D1 and D2 may, however, be of any other desired length,including zero for D1. For example, if desired, the tape 19 maysubstantially cover the entire headlap portion 76 of the overlay sheet68. It will be further understood, however, that one or more additionallengths of tape may be disposed longitudinally on the headlap portion76, even outside the nail zone, such as shown by the phantom line 19′ inFIG. 2. It will be understood that the reinforcement material need notextend from the first end 74A to the second end 74B of the shingle 74,and may be disposed in one or more sections or portions on the shingle74.

The tape 19 defines a nail zone 98 and may include text such as “nailhere”, as shown in FIG. 2. It will be understood, however, that anyother text or other indicia maybe included on the tape 19. It will alsobe understood that the tape 19 can be provided without such text orindicia. Such indicia on the tape 19 ensure that the nail zone 98 may beeasily and quickly identified by the shingle installer.

In the embodiment illustrated in FIG. 2, the underlay sheet 66 includesa leading edge 66A and a trailing edge 66B and has a third height H3. Inthe illustrated embodiment, the trailing edge 66B of the underlay sheet66 is spaced apart from the line B by a distance D3. As shown, thedistance D3 is about ⅜ inch, however, the distance D3 may be any desireddistance.

In the illustrated embodiment, the third height H3 of the underlay sheet66 is less than one-half the second height H2 of the overlay sheet 68.The overlay sheet 68 and the underlay sheet 66 thereby define atwo-layer portion of the laminated shingle 74 and a single-layer portionof the laminated shingle 74, wherein at least a portion of the tape 19is preferably adhered to the single-layer portion of the laminatedshingle 74. Alternately, the third height H3 of the underlay sheet 66may be equal to one-half the second height H2 of the overlay sheet 68,or greater than one-half of the second height H2 of the overlay sheet68. Such a relationship between the underlay sheet 66 and the overlaysheet 68 allows the tape 19 to be positioned such that a reinforced nailzone is provided at a substantially single-layer portion of the shingle74.

In another embodiment of the invention, another material, such as agranular material. Granular materials may include minerals like talc,sand, or preferably a lightweight material such as expanded shale, whichmay be applied to the first asphalt coated sheet 18 shown in FIG. 1 toin place of as the reinforcement material, or may comprise anothergranular material, such as waste materials like ground glass or rubberparticles, or may comprise polymer pellets, or other materials. Althoughsuch a material may have little or no reinforcing attributes, for thepurposes of this application, shall be considered as a “reinforcingmaterial” which provides a demarcation for the nail zone and preferablyprovides a thinner cross section and/or improved adhesion on a roof.Such a material may be nearly any material which is applied by anydesired means to an upper surface of the first asphalt coated sheet 18to achieve the desired properties. In one embodiment, the material maybe applied to the portion of the first asphalt coated sheet 18 that willbecome the portion of the overlay sheet 66 shown covered by the tape 19in FIG. 2 (and in lieu of the tape previously described). Such amaterial may preferably reduce tackiness of the portions of the secondasphalt coated sheet 22 to which the material has been applied, andthereby provide a surface to which granules substantially will notadhere and/or which creates a visible line in the overlay illustrated bythe nail zone 98. Preferably such a material provides a thinner crosssection than the granules, preferably also reduces weight versus thegranules, preferably adheres to the sealant better than the granules,and is preferably of a different color or shade than the granules toindicate the nail zone. In yet another embodiment, the reinforcingmaterial comprises the coating asphalt, whereas in such an embodiment,the asphalt is locally solidified prior to the application of granulesin order to ensure no granules adhere in this region and to representthe nail zone, or is a different asphalt composition to which granuleswould generally not adhere. Such cooling may be accomplished by applyinga another coolant locally in a controlled manner after the coatingasphalt is applied in a manner known to one skilled in the art. In yetanother embodiment, a material is applied to the asphalt coated sheet toprevent any granules from adhering to the asphalt coated sheet. Thematerial may comprise, for example, release tape, which is then removedbefore the shingle is installed, and thereby reduces the thickness ofthe shingle, the weight of the shingle, and provides an indicia for thenail zone.

In the exemplary shingle 74 illustrated in FIG. 2, the shingle 74 has anail pull-through value, preferably measured in accordance with adesired standard, such as prescribed by ASTM test standard D3462. Forexample, the shingle 74 may have a nail pull-through value that isgreater than in an otherwise identical shingle having no such tape 19.In one embodiment, the shingle 74 may have a nail pull-through valuewithin-the range of from about ten percent to about 100 percent greaterthan in an otherwise identical shingle having no such tape 19. Inanother embodiment, the shingle 74 may have a nail pull-through valueabout 50 percent greater than in an otherwise identical shingle havingno such tape 19.

In another embodiment, a shingle having a reinforcement tape 19 formedfrom polyester film having a thickness of about 0.5 mils, may have anail pull-through value about 13.3 percent greater than in an otherwiseidentical shingle having no such tape 19.

In another embodiment, a shingle having a reinforcement tape 19 formedfrom polyester film having a thickness of about 3.0 mils, may have anail pull-through value about 62.3 percent greater than in an otherwiseidentical shingle having no such tape 19.

In another embodiment, a shingle having a reinforcement tape 19 formedfrom polyester film having a thickness of about 4.0 mils, may have anail pull-through value about 86.0 percent greater than in an otherwiseidentical shingle having no such tape 19.

In another embodiment, a shingle having a reinforcement tape 19 formedfrom polyester film having a thickness of about 5.0 mils, may have anail pull-through value about 112.7 percent greater than in an otherwiseidentical shingle having no such tape 19.

Because there may be substantially no granules in the portion of theoverlay sheet 68 covered by the tape 19 (or other material describedabove, such as sand), the weight of the shingle 74 may be reducedrelative to an otherwise identical shingle having no such tape 19 ormaterial. For example, the weight of the exemplary shingle 74illustrated in FIG. 2, may be reduced within the range of from aboutfour percent to about six percent relative to the weight of an otherwiseidentical shingle having no such tape 19. The material andtransportation cost may also be reduced. In the embodiment where thetape 19 is applied to the entire headlap portion 76, the weight savingsmay approach 15 percent, 20 percent or more (in either single layer orlaminated shingles).

Although the invention has been disclosed in the context of a laminatedshingle 74, it will be understood that the reinforcement tape 19 may beattached to any other type of shingle, such as a single layer shingle.In such a single layer shingle, the reinforcement tape may require UVresistance and/or appropriate coloration if the shingle has tab cutoutsand if the tape is visible through the cutouts, and may requireelectrostatic frosting or other non-glare treatment. In a typical singlelayer shingle with cutouts, typically a band is provided at the top ofthe shingle which is not visible through the cutouts, and this zone maybe covered by the tape 19 to minimize granule usage. Furthermore, whilethe tape 19 is referred to as a reinforcing tape, the properties neednot include reinforcement characteristics.

As shown in FIG. 3, laminated roofing shingles 100 of the prior art arestacked in a bundle 102. Only a pair of such shingles 100 areillustrated in FIG. 3, with every other shingle 100 inverted and turned180 degrees. It will be understood, however, that the shingles 100 maybe stacked such that every other of such shingles 100 are eitherinverted or turned 180 degrees, or both. This stacking method minimizesuneven build in the bundle 102 caused by the difference in thicknessbetween the area of the shingle 100 that includes the underlay sheet 106and the area that does not include the underlay sheet 106. A problem mayoccur, however, along a central area 108 of the bundle 102 becausecentral areas 110 of the shingles 100 are double-layered, whereas thecutout portions 112 of the shingles 100 adjacent the central areas 110are single-layered. The difference in thickness causes a ridge or hump114 along the central area 108 of the bundle 102 that becomesprogressively higher as the number of shingles 100 in the bundle 102increases.

FIG. 4 is a schematic sectional view of a representative pair of stackedshingles 74 manufactured according to the present invention. As shown inFIG. 4, the laminated roofing shingles 74 are stacked such that everyother of the shingles 74 is inverted and turned 180 degrees relative toan adjacent one of the shingles 74 to define a bundle 99. It will beunderstood, however, that the shingles 74 may be stacked such that everyother of such shingles 74 are either inverted or turned 180 degrees, orboth. The bundle 99 includes a central area 92. In the illustratedembodiment, the central area 92 includes the lower zones 76A andreinforcement tape 19 of each shingle 74, and includes the portion ofeach laminated roofing shingle 74 wherein the shingle 74 isdouble-layered. In contrast to the prior art shingles 100, when thelaminated shingles 74 of the invention are stacked, the areas of theadjacent shingles 74 having no granules, such as the areas covered bythe reinforcement tapes 19, cooperate to advantageously reduce humpingin the central area 92 of the bundle of stacked shingles 74. As bestshown in FIG. 4, the central area 92 of the bundle, as represented bythe pair of shingles 74 illustrated, has a fourth height H4substantially identical to a fifth height H5 of a remainder of thebundle outside of the central area 92.

Additionally, a sealant is applied to a surface of the shingle toprovide a bond between shingles on a roof. During a typical shinglemanufacturing process, a pattern of adhesive is applied to the headlapportion of the shingles, so that the tab portion of the subsequentlylaid course of shingles on the roof will adhere to the headlap portionof the lower course. The adhesive bond helps to prevent wind uplift ofthe shingles on the roof. Alternatively, the sealant is applied to thebottom surface of the underlay at the leading edge 66A to bond to theheadlap portion of a shingle installed in the previous course ofshingles. It may be necessary to select a reinforcement tape 19 whichadheres to the sealant, and in some instances tape 19 may be selected toimprove the adhesion of the shingles. In one example, a 2-part adhesiveis used as the sealant, where the tape 19 activates the sealant. In apreferred embodiments, the sealant is selected to be adhesivelycompatible with the reinforcement, and may be otherwise modified toimprove adhesion to the reinforcement in a manner known to one skilledin the art. These modifications may include adding filler (such asnanoclays), adding a rubber component and such.

While the illustrations show a laminated shingle, one skilled in the artappreciates the same principles apply to a strip shingle. In such aninstance, where the strip shingle includes cutouts, the reinforcementmay be visible, and therefore must have properties to serve in anexposed environment, to provide weatherability and durability for thefinished shingle when exposed on a roof. Where the shingle does not havecutouts, such as Skyview® manufactured by Owens Corning, most of theprinciples described above with respect to laminated shingles apply.

The principle and mode of operation of this invention have beendescribed in its various embodiments. However, it should be noted thatthis invention may be practiced otherwise than as specificallyillustrated and described without departing from its scope.

1. A roofing shingle (74) comprising: an asphalt-coated sheet (18)including a tab portion (78) normally exposed on a roof and a headlapportion (76) normally covered-up on a roof, said headlap portion havinga lower zone (76A) extending longitudinally between a first end (74A)and a second end (74B) of said roofing shingle adjacent said tabportion, and an upper zone (76B) adjacent said lower zone, wherein atleast a portion of said asphalt-coated sheet has granules adheredthereto; and a reinforcement member (19) adhered to said lower zone ofsaid headlap portion.
 2. The roofing shingle according to claim 1,wherein said headlap portion has substantially no granules adheredthereto.
 3. The roofing shingle according to claim 1, wherein said lowerzone of said headlap portion has substantially no granules adheredthereto.
 4. The roofing shingle according to claim 1, wherein saidreinforcement member has substantially no granules adhered thereto. 5.The roofing shingle according to claim 4, wherein said reinforcementmember extends longitudinally between a first end (74A) and a second end(74B) of said roofing shingle.
 6. The roofing shingle according to claim5, wherein said reinforcement member is adhered to a downwardly facingsurface of said roofing shingle when said roofing shingle is installedon a roof.
 7. The roofing shingle according to claim 1, wherein thereinforcement member defines a nail zone (98).
 8. The roofing shingleaccording to claim 7, wherein said nail zone has a nail pull-throughvalue within the range of from about 10 percent to about 100 percentgreater than an otherwise identical roofing shingle having noreinforcement member defining said nail zone.
 9. The roofing shingleaccording to claim 7, wherein said nail zone has a nail pull-throughvalue about 50 percent greater than an otherwise identical roofingshingle having no reinforcement member defining said nail zone.
 10. Theroofing shingle according to claim 1, wherein said shingle with thereinforcement weighs less than an otherwise identical roofing shinglehaving no reinforcement member.
 11. The roofing shingle according toclaim 1, wherein said shingle with the reinforcement weighs at least twopercent less than an otherwise identical roofing shingle having noreinforcement member.
 12. The roofing shingle according to claim 1,wherein said roofing shingle is a laminated roofing shingle comprising:an underlay member (66); and an overlay member (68) attached to saidunderlay member, said overlay member having a tab portion (78) normallyexposed on a roof and a headlap portion (76) normally covered-up on aroof, said headlap portion having a lower zone (76A) adjacent said tabportion and an upper zone (76B) adjacent said lower zone, wherein atleast a portion of said overlay member has granules adhered thereto,wherein said overlay member has a first height (H2) and said underlaymember has a second height (H3), said second height being one of lessthan one-half said first height and equal to one-half said first height,said overlay member and said underlay member thereby defining a twolayer portion of said laminated shingle and a single layer portion ofsaid laminated shingle, and wherein at least a portion of saidreinforcement member is adhered to said single layer portion of saidlaminated shingle.
 13. A method of making a laminated shingle (74)comprising: coating a shingle mat (12) with roofing asphalt to make anasphalt-coated sheet (18); adhering a reinforcement member (19) to aportion of the asphalt-coated sheet; covering the asphalt-coated sheet,and optionally covering the reinforcement member, with granules to makea granule-covered sheet (40); dividing the granule-covered sheet into anoverlay sheet (68) and an underlay sheet (66), wherein the overlay sheethas a tab portion (78) normally exposed on a roof and a headlap portion(76) normally covered-up on a roof, the headlap portion having a lowerzone (76A) adjacent the tab portion and an upper zone (76B) adjacent thelower zone, and wherein the reinforcement member is adhered to the lowerzone of the headlap portion; and laminating the overlay sheet and theunderlay sheet to make the laminated shingle.
 14. The method accordingto claim 13, wherein the headlap portion has substantially no granulesadhered thereto.
 15. The method according to claim 13, wherein the lowerzone of the headlap portion has substantially no granules adheredthereto.
 16. The method according to claim 13, wherein the reinforcementmember extends longitudinally between a first end (74A) and a second end(74B) of the laminated shingle.
 17. The method according to claim 13,wherein the step of adhering the reinforcement member includes adheringthe reinforcement member to a downwardly facing surface of the laminatedshingle when the laminated shingle is installed on a roof.
 18. Themethod according to claim 13, wherein the reinforcement member defines anail zone (98).
 19. The method according to claim 13, wherein theoverlay sheet has a first height (H2) and the underlay sheet has asecond height (H3), the second height being one of less than the firstheight and equal to the first height, the overlay sheet and the underlaysheet thereby defining a two layer portion of the laminated shingle anda single layer portion of the laminated shingle, wherein at least aportion of the reinforcement member is adhered to the single layerportion of the laminated shingle.
 20. A method of making a laminatedshingle (74) comprising: coating a shingle mat (12) with roofing asphaltto make an asphalt-coated sheet (18); adhering a reinforcement member(19) to a portion of the asphalt-covered sheet; covering theasphalt-coated sheet with granules to make a granule-covered sheet (40);dividing the granule-covered sheet into an overlay sheet (68) and anunderlay sheet (66), wherein the overlay sheet has a tab portion (78)normally exposed on a roof and a headlap portion (76) normallycovered-up on a roof, the headlap portion having a lower zone (76A)adjacent the tab portion and an upper zone (76B) adjacent the lowerzone, and wherein the reinforcement member is adhered to the lower zoneof the headlap portion; and laminating the overlay sheet and theunderlay sheet to make the laminated shingle.
 21. A method of making alaminated shingle according to claim 20, wherein the step of adhering areinforcement member to a portion of the asphalt-covered sheet isperformed after the asphalt-coated sheet is covered with granules.
 22. Abundle (99) of laminated roofing shingles (74) stacked such that everyother of said shingles is at least one of inverted and turned 180degrees relative to an adjacent one of said shingles, said shingleshaving an overlay (68) laminated with an underlay (66), said overlayhaving a tab portion (78) with cutouts normally exposed on a roof and aheadlap portion (76) normally covered-up on a roof, said headlap portionhaving a lower zone (76A) adjacent said tab portion and an upper zone(76B) adjacent said lower zone, said lower zone having substantially nogranules adhered thereto, said bundle defining a central area (92) thatsubstantially encompasses said lower zones of the stacked shingles andwherein said laminated roofing shingles are double-layered, wherein thelack of granules in the lower zones of the stacked shingles results insaid central area of said bundle having a height substantially identicalto a height of a remainder of said bundle outside of said central area.23. The bundle of laminated roofing shingles according to claim 21,wherein said shingles have a reinforcement member (19) adhered to saidlower zone of said headlap portion.
 24. The bundle of laminated roofingshingles according to claim 22, wherein said reinforcement membersextend longitudinally between a first end (74A) and a second end (74B)of said overlays.
 25. The bundle of laminated roofing shingles accordingto claim 22, wherein said reinforcement members define a nail zone (98).26. A method of reducing humping (114) of a bundle (99) of stackedlaminated roofing shingles (74), the shingles having an overlay (68)laminated with an underlay (66), the overlay having a tab portion (78)with cutouts normally exposed on a roof and a headlap portion (76)normally covered-up on a roof, the headlap portion having a lower zone(76A) adjacent the tab portion and an upper zone (76B) adjacent thelower zone, the method comprising: providing the lower zone of theheadlap portion having substantially no granules adhered thereto; andstacking the shingles such that every other of the shingles is at leastone of inverted and turned 180 degrees relative to an adjacent one ofthe shingles, thereby defining a bundle of stacked laminated roofingshingles, wherein the bundle defines a central area (92) thatsubstantially encompasses the lower zones and wherein the laminatedroofing shingles are double-layered, and wherein the lack of granules inthe lower zones of the stacked shingles results in the central area ofthe bundle having a height substantially identical to a height of aremainder of the bundle outside the central area.
 27. The methodaccording to claim 26, including providing a reinforcement member (19)in the lower zones.
 28. The method according to claim 26, wherein thestep of providing the reinforcement member comprises adhering thereinforcement member to the lower zones of the headlap portions.
 29. Themethod according to claim 26, wherein the reinforcement member defines anail zone (98).
 30. The method according to claim 26, wherein the lackof granules results in the shingle weighing less than an otherwiseidentical roofing shingle having no reinforcement member.
 31. A methodof making a shingle (74) comprising: coating a shingle mat (12) withroofing asphalt to make an asphalt-coated sheet (18); providing amaterial (19) other than roofing granules to a portion of theasphalt-coated sheet prior to applying granules thereto to define a nailzone (98); covering the asphalt-coated sheet, and optionally coveringthe material, with granules to make a granule-covered sheet (40);dividing the granule-coveted sheet into a shingle which includes a firstportion (78) normally exposed on a roof and a headlap portion (76)normally covered-up on a roof, the headlap portion having a lower zone(76A) adjacent the first portion and an upper zone (76B) adjacent thelower zone, and wherein the material is adhered to the lower zone of theheadlap portion (76).
 32. The method according to claim 31, wherein theheadlap portion (76) has substantially no granules adhered thereto. 33.The method according to claim 31, wherein the lower zone (76A) of theheadlap portion has substantially no granules adhered thereto.
 34. Themethod according to claim 31, wherein the material extendslongitudinally between a first end (74A) and a second end (74B) of theshingle.
 35. The method according to claim 31, further comprising thesteps of: dividing the granule-covered sheet into an overlay sheet (68)and an underlay sheet (66), wherein the overlay sheet has a tab portion(78) normally exposed on a roof and a headlap portion (76) normallycovered-up on a roof, the headlap portion having a lower zone (76A)adjacent the tab portion and an upper zone (76B) adjacent the lowerzone, and wherein the reinforcement member is adhered to the lower zoneof the headlap portion; and laminating the overlay sheet and theunderlay sheet to make the laminated shingle.
 36. The method accordingto claim 31, wherein the shingle comprises a nonlaminated shingle. 37.The method according to claim 31, wherein the material (19) providessubstantially no improved strength or nail pull through.
 38. The methodaccording to claim 31, wherein the material (19) is removed prior tosecuring the shingle to the roof.
 39. The method according to claim 31,wherein the nail zone (98) has a nail pull-through value within therange of from about 10 percent to about 100 percent greater than anotherwise identical roofing shingle having no reinforcement memberdefining said nail zone.
 40. The method according to claim 31, whereinthe material (16) comprises a granular material.
 41. The methodaccording to claim 31, wherein the material (16) comprises a film. 42.The method according to claim 31, wherein the material (16) comprises awoven or nonwoven fabric.
 43. The method according to claim 31, whereinthe material (16) provides improved adhesion of the shingle to a sealantprovided on a second roofing shingle.
 44. The method according to claim31, wherein the material (16) results in the shingle weighing less thanan otherwise identical roofing shingle having roofing granules in placeof the material.